Seat support

ABSTRACT

A seat support is provided with a plurality of layers of a non-foam material to mount to a seat frame and to support an occupant upon the seat frame. The plurality of layers is stacked upon each other. At least one of the plurality of stacked layers has a generally uniform thickness.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application Ser. No. 17/218,663 filed Mar. 31, 2021, now U.S. Pat. No. ______, the disclosure of which is hereby incorporated in its entirety by reference herein.

TECHNICAL FIELD

Various embodiments relate to seat supports, methods for manufacturing seat supports and seat assemblies, and methods for recycling seat supports and seat assemblies.

BACKGROUND

Duncan et al. U.S. Pat. No. 10,736,435 B2 issued on Aug. 11, 2020, to Lear Corporation teaches a seat part that includes a non-foam base material.

SUMMARY

According to an embodiment, a seat support is provided with a plurality of layers of a non-foam material to mount to a seat frame and to support an occupant upon the seat frame. The plurality of layers is stacked upon each other, and each of the plurality of stacked layers has a generally uniform thickness.

According to a further embodiment, one of the plurality of layers has a first firmness. Another of the plurality of layers has a second firmness that differs from the first firmness.

According to another further embodiment, one of the plurality of layers has a first thickness. Another of the plurality of layers has a second thickness that differs from the first thickness.

According to another further embodiment, wherein a plurality of zones is provided. At least two of the zones vary in thickness, firmness, or a quantity of stacked layers.

According to an even further embodiment, the plurality of zones is further provided with a nose, an insert, and a pair of bolsters on opposed lateral sides of the nose and the insert to support a seat bottom.

According to another even further embodiment, the plurality of zones is further provided with an insert, a pair of bolsters on opposed lateral sides of the insert, and a pair of shoulders on opposed lateral sides of the insert to support a seat back.

According to another further embodiment, each of the plurality of layers is formed from a monofilament textile material.

According to another further embodiment, each of the plurality of layers is formed from a recycled material.

According to another further embodiment, each of the plurality of layers is formed from polyester.

According to another even further embodiment, a heater mat or a blower is provided.

According to an even further embodiment, a sealed ventilation port is formed through at least one of the layers.

According to another even further embodiment, a region between a sequential pair of layers is sealed so that ventilation is directed through one of the sequential pair of layers.

According to another further embodiment, a conductive yarn is provided within the one of the layers of monofilament textile material.

According to another even further embodiment, a heater mat is oriented between two of the plurality of layers. The heater mat is in electrical communication with the conductive yarn.

According to another further embodiment, each sequential pair of layers are welded or sewn together.

According to another further embodiment, each layer is further provided with one of a hook and loop fastener to fasten to a sequential layer of the plurality of layers.

According to another further embodiment, each of the plurality of layers is formed from a similar recyclable material.

According to an even further embodiment, an adhesive is provided between each sequential pair of the plurality of layers to adhere sequential layers together. The adhesive is formed from the similar recyclable material.

According to another embodiment, a seat assembly is provided with a substrate. A seat support is provided with a plurality of layers of a non-foam material to mount to a seat frame and to support an occupant upon the seat frame. The plurality of layers is stacked upon each other, and each of the plurality of stacked layers has a generally uniform thickness. Each of the plurality of layers is formed from a monofilament textile material. The seat support is attached to the substrate.

According to a further embodiment, a seat frame is provided. The substrate is attached to the seat frame.

According to another further embodiment, each of the plurality of layers is formed from a similar recyclable material. The substrate is formed from the similar recyclable material.

According to another embodiment, a seat assembly is provided with a seat support with a plurality of layers of a non-foam material to mount to a seat frame and to support an occupant upon the seat frame. The plurality of layers is stacked upon each other, and each of the plurality of stacked layers has a generally uniform thickness. Each of the plurality of layers is formed from a monofilament textile material. Each of the plurality of layers is formed from a similar recyclable material. A trim cover is sized to receive the seat support.

According to a further embodiment, the trim cover is formed from the similar recyclable material as the plurality of layers.

According to another further embodiment, the trim cover is formed from a single leather layer without coatings.

According to another further embodiment, a trim clip is provided to connect the trim cover to the seat support. The trim clip is formed from the similar recyclable material as the plurality of layers.

According to another embodiment, a method for manufacturing a seat assembly cuts a first seat support portion from a first sheet of monofilament material. The first seat support portion is installed upon a substrate. A trim cover is installed over the first seat support portion.

According to a further embodiment, the sheet of monofilament material is unrolled before cutting the first seat support portion.

According to another further embodiment, the first seat support portion is cut with a laser.

According to another further embodiment, a plurality of seat support portions is cut from the first sheet of monofilament material. The plurality of seat support portions is stacked to form a seat support.

According to an even further embodiment, one of the plurality of seat support portions is sealed to direct ventilation through the seat assembly.

According to another even further embodiment, a dust is formed through one of the plurality of seat support portions to direct ventilation through the seat assembly.

According to another even further embodiment, the plurality of seat support portions is fastened together.

According to another further embodiment, a second seat support portion is cut from a second sheet of monofilament material that differs from the first sheet of monofilament material in firmness or thickness. The first seat support portion and the second seat support portion are stacked to form a seat support.

According to another further embodiment, a first plurality of seat support portions is cut from the first sheet of monofilament material. A second plurality of seat support portions is cut from a second sheet of monofilament material. The first plurality of seat support portions and the second plurality of seat support portions are stacked in zones to form a seat support.

According to another further embodiment, a polymeric material is recycled. The first sheet of monofilament material is manufactured from the recycled polymeric material.

According to an even further embodiment, the substrate is manufactured from the recycled polymeric material.

According to another even further embodiment, the trim cover is manufactured from the recycled polymeric material.

According to another even further embodiment, a plurality of seat support portions is adhered together with an adhesive of the recycled polymeric material.

According to another embodiment, a seat support assembly is provided with a non-foam monofilament textile material to mount to a seat frame and to support an occupant upon the seat frame. A heater mat or a blower is provided. The monofilament textile material permits ventilation without an air distribution bag.

According to a further embodiment, a sealed ventilation port is formed through the monofilament textile material.

According to another further embodiment, a region through the monofilament textile material is sealed so that ventilation is directed through the monofilament textile material.

According to another embodiment, a method for recycling a seat assembly a seat support from a polymeric material is ground. A trim clip or a trim cover from a similar polymeric material as the seat support is ground without disassembling the trim clip or the trim cover from the seat support.

According to a further embodiment, the trim clip and the trim cover from the similar polymeric material as the seat support are ground without disassembling the trim clip or the trim cover from the seat support.

According to another further embodiment, a substrate from a similar polymeric material as the seat support is ground without disassembling the substrate from the seat support.

According to another further embodiment, an adhesive from a similar polymeric material as the seat support is ground without removing the adhesive from the seat support.

According to another further embodiment, a roll of a monofilament material is manufactured from the ground polymeric material.

According to another embodiment, a seat support is provided with a plurality of layers of a non-foam material to mount to a seat frame and to support an occupant upon the seat frame. The plurality of layers is stacked upon each other. At least one of the plurality of stacked layers has a generally uniform thickness.

According to a further embodiment, the plurality of layers is further provided with a base layer to mount to the seat frame. A second layer is mounted to the base layer. The second layer has the generally uniform thickness.

According to an even further embodiment, the base layer has a first firmness. The second layer has a second firmness that is less firm than the first firmness.

According to another even further embodiment, the base layer has a first thickness. The second layer has a second thickness that is less than the first thickness.

According to another even further embodiment, the base layer is formed from a monofilament textile material.

According to another even further embodiment, the second layer is formed from a monofilament textile material.

According to another even further embodiment, the second layer is formed from polyester.

According to another even further embodiment, the second layer is welded, sewn, or adhered to the base layer.

According to another further embodiment, a plurality of zones is provided, wherein at least two of the zones vary in thickness, or firmness.

According to an even further embodiment, the plurality of zones is further provided with a nose, an insert, and a pair of bolsters on opposed lateral sides of the nose and the insert to support a seat bottom.

According to another even further embodiment, the plurality of zones is further provided with an insert, a pair of bolsters on opposed lateral sides of the insert, and a pair of shoulders on opposed lateral sides of the insert to support a seat back.

According to another embodiment, a seat assembly is provided with a substrate. A seat support is provided with a plurality of layers of a non-foam material to mount to a seat frame and to support an occupant upon the seat frame. The seat support is attached to the substrate. The plurality of layers is stacked upon each other. At least one of the plurality of stacked layers has a generally uniform thickness. The plurality of layers is further provided with a base layer to mount to the seat frame. A second layer is mounted to the base layer. The second layer has the generally uniform thickness.

According to a further embodiment, the seat frame is provided, and the substrate is attached to the seat frame.

According to another embodiment, a seat assembly is provided with a seat support with a plurality of layers of a non-foam material to mount to a seat frame and to support an occupant upon the seat frame. The plurality of layers is stacked upon each other. At least one of the plurality of stacked layers has a generally uniform thickness. The plurality of layers is further provided with a base layer to mount to the seat frame. A second layer is mounted to the base layer. The second layer has the generally uniform thickness. A trim cover is sized to receive the seat support with the second layer oriented between the trim cover and the base layer.

According to another embodiment, a method for manufacturing a seat assembly forms a base seat support portion. A second seat support portion is cut from a sheet of monofilament material. The second seat support portion is installed upon the base seat support portion.

According to a further embodiment, a trim cover is installed over the base seat support portion and the second seat support portion so that the second seat support portion is oriented between the base seat support portion and the trim cover.

According to another further embodiment, the second seat support portion is fastened to the base seat support portion.

According to even another further embodiment, the base seat support portion is formed from a non-foam material.

According to another embodiment, a seat assembly is manufactured by forming a base seat support portion. A second seat support portion is cut from a sheet of monofilament material. The second seat support portion is installed upon the base seat support portion.

According to even another embodiment, a method for manufacturing a seat assembly forms a base seat support portion from a non-foam material. A second seat support portion is cut from a sheet of monofilament material. The second seat support portion is installed upon the base seat support portion. The second seat support portion is fastened to the base seat support portion. A trim cover is installed over the base seat support portion and the second seat support portion so that the second seat support portion is oriented between the base seat support portion and the trim cover.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective partial section view of a seat assembly according to an embodiment;

FIG. 2 is a perspective section view of a portion of the seat assembly of FIG. 1 according to another embodiment;

FIG. 3 is a perspective view of a portion of the seat assembly of FIG. 1 according to another embodiment;

FIG. 4 is a perspective view of a portion of a seat assembly according to an embodiment;

FIG. 5 is an exploded section view of a fastener assembly of a seat assembly according to another embodiment;

FIG. 6 is a perspective view of a trim clip of a seat assembly according to an embodiment;

FIG. 7 is a perspective view of a seat assembly according to another embodiment;

FIG. 8 is a front elevation view of the seat assembly of FIG. 7;

FIG. 9 is a perspective partial section view of a seat assembly according to another embodiment;

FIG. 10 is a section view of a portion of the seat assembly of FIG. 9;

FIG. 11 is a section view of another portion of the seat assembly of FIG. 9;

FIG. 12 is a perspective partial section view of a seat assembly according to another embodiment;

FIG. 13 is an exploded view of portions of the seat assembly of FIG. 12;

FIG. 14 is a front perspective view of the seat assembly of FIG. 12, illustrated with a trim cover removed;

FIG. 15 is a front perspective view of a seat assembly according to another embodiment; and

FIG. 16 another front perspective view of the seat assembly of FIG. 15.

DETAILED DESCRIPTION

As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

Seat assemblies, and vehicle seat assemblies are designed and manufactured in light of various specifications, including support, comfort, performance, heating, ventilation, cooling, adjustability, and the like. Seat assemblies are often provided with a frame, and various layers of foam with varying densities to accommodate an applicable load distribution across the seat assembly.

FIG. 1 illustrates a seat assembly 20 according to an embodiment. The seat assembly 20 is depicted as a vehicle seat, which may be employed as a seat assembly in a land vehicle, an aircraft, a watercraft, or the like. The seat assembly 20 may be employed within any row within the vehicle. Alternatively, the seat assembly 20 may also be employed as an office chair, or any individual chair. The seat assembly 20 omits traditional foam, in order to improve support and comfort, while reducing costs, material and size. The seat assembly 20 also employs recycled materials, which are manufactured for further recycling at the end of use of the seat assembly 20.

The seat assembly 20 includes a seat bottom 22, which is sized to receive a seated occupant to support a pelvis and thighs of the occupant. The seat assembly 20 also includes a seat back 24 sized to extend upright from the seat bottom 22 to support a back of the occupant. A head restraint 26 is supported upon and above the seat back 24 to support a head of the occupant. The seat bottom 22 is adapted to be supported by an underlying support surface. For the depicted embodiment, the seat assembly 20 includes a pair of rails 28 for mounting the seat bottom 22 to a vehicle floor for fore and aft adjustment relative to the vehicle floor. The seat back 24 may also be adjustable for recline relative to the seat bottom 22. The head restraint 26 may also be adjustable in height, tilt, and fore/aft directions. Other adjustments may be provided, as are known in the art.

The seat bottom 22 includes a frame 30 for providing rigid structural support to the seat bottom 22. The seat back 24 also includes a frame 32. The seat back frame 32 may be connected to the seat bottom frame 30 to extend upright from the seat bottom 22. The seat back frame 32 provides rigid structural support to seat back 24. The frame 30, 32 may be formed from a stamped steel alloy, a fiber reinforced polymer, or any suitable structural material. A pair of head restraint posts 34 are connected an upper region of the seat back frame 32 to support the head restraint 26 above the seat back 24.

Conventional seating assemblies include a plurality of foam layers to collectively provide cushioning upon the frames 30, 32 and the head restraint 26 upon the posts 34. The foam layers vary in density to provide compliant support to the occupant while distributing forces from the occupant to the frames 30, 32 and the posts 34. The foam layers also provide comfort to the occupant. The foam layers are often molded, thereby requiring dedicated tooling for each foam layer of each seating assembly.

The seat assembly 20 is formed without foam to improve comfort, performance, compactness, and recycling, while reducing manufacturing tooling costs. For example, the seat assembly 20 includes a seat bottom support 36, which provides the seat bottom cushion for the seat bottom 22. The seat bottom support 36 is formed from a plurality of stacked layers of a non-foam material. The seat back 24 includes a seat back support 38 that is also formed of the non-foam stacked layers. Likewise, the head restraint 26 may also be provided with a head restraint support 40 formed from the non-foam stacked layers.

FIG. 2 illustrates a plurality of the stacked layers 42, 44, 46 that are employed to construct the seat bottom support 36, the seat back support 38 and the head restraint support 40. Each of the layers 42, 44, 46 depicted is formed from a knitted monofilament textile material. An example of the material is a polyester, such as polyethylene terephthalate. The material may also be formed from a recycled material to reduce material costs, and to reduce waste. The material of each of the layers 42, 44, 46 is a similar polyester, so that the entire seat support 36, 38, 40 can be recycled without disassembly of the individual layers 42, 44, 46.

The material is knitted or woven to provide structure, while also spaced out to provide porosity, ventilation, and compliancy. The layers 42, 44, 46 each may have a uniform thickness, and may be formed from sheets, or rolled sheets of material. The layers 42, 44, 46 may each vary by firmness or thickness. An example of a knitted non-foam material is disclosed in Duncan et al. U.S. Pat. No. 10,736,435 B2, which issued to Lear Corporation on Aug. 11, 2020, and is incorporated in its entirety by reference herein.

The layers 42, 44, 46 may be customizable. The layers 42, 44, 46 may each be formed from a specific firmness and thickness, so that varying combinations of the layers 42, 44, 46 can be employed to optimize a specified support and comfort curve profile for a variety of seats. The firmness of a layer 42, 44, 46 can be modified by modifying a density of the layer, density of the threads in the layer, thickness of the threads in the layer, spacing of the threads in the layer, and the like. Comfort curve profiles are developed by estimated pressure distributions across the seat assembly 20 based on set design characteristics for occupants based on predicted heights, weights, and other data for a target range of occupants. Seat assemblies 20 that utilize stacked layers 42, 44, 46 instead of polyurethane foam and that are designed to provide the same static comfort reduce up to two pounds in weight in comparison to the same seat assembly made with foam. Additionally, the stacked layers 42, 44, 46 permit more design flexibility to reduce pressure in peak areas in the seat assembly 20.

A range of varying thicknesses may be provided by the layers 42, 44, 46, 48 that can be combined for the target thickness of the seat supports 36, 38, 40. According to one example, each layer may have a thickness within a range of six to fifteen millimeters.

FIG. 3 illustrates another non-foam monofilament textile that provides one of the layers 48. The textile is formed as a rolled good. The layers 42, 44, 46, 48 may each vary in knit pattern. For example, the layers 42, 44, 46, 48 may be formed with concealed surfaces, known as B surfaces in the art. Some layers may be formed with a surface designed to be exposed, known as a face cloth, or an A surface, such as the face cloth surface 50 of the layer 48 in FIG. 3. By providing the face cloth surface 50 on one of the layers, an external trim cover may be minimized or eliminated.

Each seat support 36, 38, 40 is formed from a plurality of the stacked layers 42, 44, 46, 48. The layers 42, 44, 46, 48 may each be unrolled, and then cut to a specified trim pattern. According to an embodiment, the layers 42, 44, 46, 48 are cut by a laser. According to another embodiment, the layers are cut by automation, such as robotic tooling. By cutting the layers 42, 44, 46, 48, trim dies and foam molds are eliminated, thereby reducing the tooling costs for manufacturing the seat assemblies 20.

The layers 42, 44, 46, 48 are then stacked together to form the seat supports 36, 38, 40. Referring again to FIG. 1, the seat bottom frame 30 may be formed as a pan. Each of the layers 42, 44, 46, 48 can be stacked and nested into a pan-shaped frame 30. Alternatively, a substrate, such as a carrier or pan 52 can be provided in the seat bottom 22 to receive the layers 42, 44, 46, 48, and to connect the layers to the frame 30. Likewise, the seat back frame 32 can also be formed as a pan. A seat back carrier 54 may be provided separately to support and attach the layers 42, 44, 46, 48 to the frame 30. A head restraint carrier 56 may also be provided to support the layers 42, 44, 46, 48, and to attach the layers 42, 44, 46, 48 to the posts 34.

FIG. 4 illustrates the seat back carrier 54 according to an embodiment. The seat back carrier 54 has a general overall shape and contour of the seat back 24. The seat back carrier 54 may also be provided with other functional components that are placed beneath the cushioning of the seat back support 38. For example, a plurality of air bladders 58 are attached to the carrier 54. The air bladders 58 may be employed for support, posture, and comfort adjustment to the seat back 24.

Each of the layers 42, 44, 46, 48 can be stacked and nested into each of the carriers 52, 54, 56 to build each of the seat supports 36, 38, 40. Each of the carriers 52, 54, 56 may also be formed of the same polyester material as the layers 42, 44, 46, 48. Therefore, the seat supports 36, 38, 40 can be recycled at the end of use without disassembling the layers 42, 44, 46, 48 from the carriers 52, 54, 56.

Each of the layers 42, 44, 46, 48 may be fastened together to form each seat support 36, 38, 40. According to one embodiment, a polyester adhesive is provided between adjacent layers 42, 44, 46, 48 to adhere the layers together 42, 44, 46, 48. The polyester adhesive can be recycled with the layers 42, 44, 46, 48 without removal before recycling. The polyester adhesive may be heat activated, wherein the assembled layers 42, 44, 46, 48 are heated to bond together. Polyester adhesive is less susceptible to deterioration over time, and from being subjected to variations in temperature and humidity. The polyester adhesive may be knitted into external threads of the layers 42, 44, 46, 48 according to an example.

Alternatively, the layers 42, 44, 46, 48 can be welded together, such as by a radiofrequency weld. The fastening of the layers 42, 44, 46, 48 by welding can also be automated. Other mechanisms for fastening adjacent layers includes, sewing, embroidery, quilting and the like. Sequential layers 42, 44, 46, 48 can be provided with a one of a hook and loop fastener to connect to each other.

FIG. 5 illustrates two layers 72 each formed with a loop fastener 74 formed about the layers 72. An intermediate hook layer 76 is provided with an array of external hooks 78 to fasten to the loops 74 of the sequentially adjacent layers 72. Each of the layers 72, 76, and the fasteners 74, 78 are formed from polyester for recycling with the seat support 36, 38, 40.

Referring again to FIG. 1, once the stacked layers 42, 44, 46, 48 are assembled, the seat supports 36, 38, 40 are provided on the carriers 52, 54, 56. A trim cover 60, 62, 64 is provided over each seat support 36, 38, 40. The seat bottom trim cover 60, the seat back trim cover 62, and the head restraint trim cover 64 may each be formed from the polyester material. Therefore, the trim covers 60, 62, 64 can be recycled with the seat supports 36, 38, 40 without being removed from the seat supports 36, 38, 40. The trim covers 60, 62, 64 may be formed from sustainable materials, such as reprieve yarns, polyester based textiles, or leather alternatives.

Alternatively, the trim covers 60, 62, 64 can be formed from leather. The leather trim covers 60, 62, 64 may each be formed from a single material base without coatings to allow for end of use recycling. The leather trim covers 60, 62, 64 may be removed from the seat supports 36, 38, 40 for recycling separate from the seat supports 36, 38, 40.

FIG. 6 illustrates a trim clip 66 according to an embodiment. The trim clip 66 may function as is known in the art, with a base 68 that is sized to be received in a trench within one of the seat supports 36, 38, 40. The trim clip 66 also includes a pair of retainers 70 extending from the base 68. The retainers 70 receive a portion of the trim cover 60, 62, 64 to attach the trim cover 60, 62, 64 to the seat support 36, 38, 40. Although one trim clip 66 example is illustrated and described, any suitable trim clip may be employed. Multiple trim clips 66 may be employed, and may be interconnected, or tethered in arrays or strips known as ganged clips 66. The trim clips 66 may also be formed from the similar recyclable material, polyester. If tethered, then the tethers may also be formed from polyester. Due to the similar material, the trim clips 66 can be recycled with the seat supports 36, 38, 40 without being disassembled from the seat supports 36, 38, 40.

The various components for the seat assemblies 20 can be formed from a recycled material to reduce a carbon footprint. Additionally, at the end of the life, the seat supports 36, 38, 40 can be disassembled from the frames 30, 32, and posts 34 for recycling. For recycling, the polyester components can be ground together without disassembly. The recycled material can be repurposed. The recycled material may also be fabricated into rolls of monofilament textile material for fabricating new seat assemblies 20.

By eliminating foam from the seat assembly 20, molds and dies can be eliminated thereby reducing tooling costs. The flexibility of laser cutting lowers maintenance costs and increases part quality. The recyclability of the materials reduces scrap waste. Additionally, chemical usage is reduced in the manufacturing process.

The seat assembly 20 is lighter than a comparable seat fabricated with foam cushioning. The seat assembly 20 is also more compact in size. Targeted comfort layers are provided and can be easily redesigned for future models or options without additional tooling costs.

FIGS. 7 and 8 illustrate a seat assembly 80 according to another embodiment. Similar to the prior embodiment, the seat assembly 80 includes a seat bottom 82, a seat back 84 and a head restraint 86. The seat bottom 82 includes a seat bottom support 88 formed from a plurality of zones. For example, the seat bottom 82 may include an insert 90 oriented centrally at a rear of the seat bottom 82 and sized to receive the pelvis of the occupant. A nose 92 is oriented forward of the insert 90 and is sized to support the occupant's thighs. A pair of bolsters 94 are each oriented laterally outboard of the insert 90 and the nose 92 to provide lateral support and comfort to the pelvis and thighs.

Each zone 90, 92, 94 of the seat bottom support 88 is formed from a plurality of stacked layers so that the zones vary in thickness and firmness. According to one embodiment the seat bottom support 88 is formed from four separate material sheets that vary in firmness, from firm, semi-firm, semi-soft, and soft. Each of these zones may be constructed from multiple layers of the material sheets. For example, the insert 90 may formed from the bottom to the top with five layers in sequence: firm, firm, semi-soft, semi-soft and soft. The nose 92 supports less weight and is provided from five layers in sequence: semi-firm, semi-soft, soft, soft, and soft. The bolsters 94 are a little more rigid and are stacked in sequence from the bottom: firm, firm, semi-firm, semi-soft, and semi-soft. Each zone 90, 92, 94 is somewhat rigid at the base to provide support and softens near the surface to provide comfort. The zones 90, 92, 94 vary in construction to provide a target comfort profile based on the estimated pressure distribution. The construction of the zones 90, 92, 94 is by way of example to illustrate how a targeted comfort profile can be provided with a variety of four material layers, stacked in a quantity of up to five layers. Any quantity of layers may be employed within any zone to obtain the targeted support and comfort profile.

The seat back 84 includes a seat back support 96. The seat back support 96 includes a plurality of zones. For example, a seat back insert 98 supports lumbar and thoracic regions of the back of the occupant. A pair of seat back bolsters 100 are spaced apart laterally about the insert 98 to provide lateral support to the occupant's back. A pair of shoulder zones 102 are provided above the bolsters 100 and extend from lateral sides of the insert 98 to the head restraint 86.

The seat back 84 supports lighter loads than the seat bottom 82. According to an embodiment, the seat back support 96 is formed from various combinations of the four material layers that are utilized for the seat bottom support 88. The insert 98 is provided from five layers from back to front in sequence: semi-firm, semi-firm, semi-firm, semi-firm and semi-soft. The bolsters 100 are thinner and are provided by four layers in sequence from rear to front: semi-firm, semi-firm, semi-firm, and semi-soft. The shoulders 102 are provided with one layer, semi-soft. The comfort profile can also vary based on the quantity of material layers as exemplified by the seat back support 96.

FIG. 9 depicts a seat assembly 110 according to another embodiment. The seat assembly 110 includes a seat bottom 112, a seat back 114, and a head restraint 116. The seat assembly 110 includes rails 118 for connection to a vehicle floor. The seat bottom 112 includes a seat bottom support 120 formed from multiple layers of the monofilament textile as described above in prior embodiments. Likewise, the seat back 114 includes a seat back support 122 also formed from multiple non-foam layers. A trim cover 124 is provided over the seat bottom 112. A seat back trim cover 126 is provided over the seat back 114. A heater 128 is provided between layers in the seat bottom support 120. A cooling layer 130 is also provided with the seat bottom support 120.

FIG. 10 is a partial section view of the seat bottom support 120 through the heater 128. The seat bottom 112 includes a seat bottom carrier 132. The seat bottom carrier 132 may be provided with vents to permit ventilation through and underneath the seat bottom 112. A plurality of layers 134 of the monofilament material are provided on the carrier 132. The heater 128 is provided upon the layers 134. The porosity of the monofilament textile material 134 permits ventilation through the layers 134. Therefore, additional ducting or a ventilation distribution bag are omitted in contrast to the prior art.

Another monofilament textile layer 136 is provided on top of the layers 134 with the heater 128 therebetween. The upper layer 136 may permit heat to pass therethrough to conduct and convey heat through the upper layer 136 to the trim cover 124. The upper layer 136 may be formed with a thermally conductive yarn to conduct heat from the heater 128 to the trim cover 124. The conductive yarn may include a thermally conductive carbon fiber. One of the layers 134, 136 beneath or above the heater 128 may be formed with a conductive thread to convey electricity to the heater 128. Townley et al. U.S. Pat. No. 10,882,444 B2 issued to Lear Corporation on Jan. 5, 2021 and discloses a textile with a conductive element, which is incorporated in its entirety by reference herein.

FIG. 11 illustrates a partial section view of the seat bottom support 120 through the cooling layer 130 according to an embodiment. A cooling assembly 138 is attached to the carrier 132. The cooling assembly 138 includes a blower fan as is known in the art. The cooling assembly 138 may also include a thermoelectric device, which includes a module for cooling the forced air. A plurality of layers 140 are provided on the substrate 132, between the substrate 132 and the cooling layer 130. A port 142 is formed through the layers 140 to direct the forced air through the layers 140. The port 142 is sealed to prevent the forced air from indirectly passing through the intermediate layers 140.

The forced air is conveyed to the cooling layer 130. Due to the porosity of monofilament layer 130, the forced air disperses through the monofilament layer 130 to cool the trim cover 124. A seal 144 is also provided between the cooling layer 130 and the adjacent intermediate layer 140 to prevent the cooled air from passing into the intermediate layers 140. The seals 144 direct the air and mitigate airflow loss. The seals 144 may also be formed of a polyester material for recycling with the seat bottom 112. The monofilament layers permit improved thermal comfort and energy efficiency in the seat assembly 110.

FIGS. 12 and 13 illustrate a seat assembly 150 according to another embodiment. The seat assembly 150 may employ any of the features set forth in the prior embodiments. The seat assembly 150 includes a seat bottom 152, a seat back 154, and a head restraint 156. For the depicted embodiment, the seat assembly 150 includes a pair of rails 158 for mounting the seat bottom 152 to a vehicle floor for fore and aft adjustment relative to the vehicle floor. The seat bottom 152 includes a frame 160; and the seat back 154 includes a frame 162.

The seat assembly 150 is formed without foam to improve comfort, performance, compactness, and recycling, while reducing manufacturing tooling costs. For example, the seat assembly 150 includes a seat bottom support 166, which provides the seat bottom cushion for the seat bottom 152. The seat bottom support 166 is formed from a plurality of stacked layers of a non-foam material. The seat back 154 includes a seat back support 168 that is also formed of the non-foam stacked layers.

FIGS. 12 and 13 illustrate that the seat bottom support 166 includes a seat bottom base layer 172 and a seat bottom comfort layer 174. The seat back support 168 also includes a seat back base layer 176 and a seat back comfort layer 178. The seat bottom base layer 172 and the seat back base layer 176 are formed from a knitted monofilament textile material. The base layers 172, 176 are knitted or woven to provide structure, while the material is also spaced out to provide porosity, ventilation, and compliancy. The base layers 172, 176 may each vary by firmness or thickness and may be contoured to form a shape of the seat bottom support 166 and the seat back support 168, respectively. The base layers 172, 176 may be formed from an extruded plastic mesh material. Alternatively, another example of the knitted non-foam material of the base layers 172, 176 is disclosed in Duncan et al. U.S. Pat. No. 10,736,435 B2, which issued to Lear Corporation on Aug. 11, 2020, and is incorporated in its entirety by reference herein. According to another example, the base layers 172, 176 may each be formed from sheets, or rolled sheets of material.

The seat bottom comfort layer 174 and the seat back comfort layer 178 are also formed from a knitted monofilament textile material as disclosed in Duncan et al. U.S. Pat. No. 10,736,435 B2, which issued to Lear Corporation on Aug. 11, 2020, and is incorporated in its entirety by reference herein. The material is knitted or woven to provide structure, while also spaced out to provide porosity, ventilation, and compliancy. Alternatively, the layers 174, 178 may each have a uniform thickness, and may be formed from sheets, or rolled sheets of material. The layers 174, 178 may each vary by firmness or thickness.

The base layers 172, 176 may each be formed with a varying firmness, while sufficiently firm to support comfort layers 174, 178 and the occupant. The comfort layers 174, 178 may be formed with a second firmness, which is less than the firmness of the base layers 172, 176 to provide more compliancy and comfort between the occupant and the base layers 172, 176. The comfort layers 174, 178 may each have a uniform thickness, which is less than the overall thickness of the base layers 172, 176 to provide adequate compliancy and a luxury contact with the occupant. The combination of one of the base layers 172, 176 with one of the comfort layers 174, 178 permits a multi-layered, non-foam, monofilament textile seat support 166, 168 with minimal gaps (five millimeters or less) between the transitions from one layer to another.

The comfort layers 174, 178 may be fastened to the support layers 172, 176 by welding, stitching, adhesive, or the like. A trim cover 180 is illustrated in FIG. 12 disposed over the seat bottom support 166 and the seat back support 168 to conceal the frames 160, 162, the seat bottom support 166, the seat back support 168 and any other components supported upon the frames 160, 162. The comfort layers 174, 178 are oriented between the support layers 172, 176 and the trim cover 180 to provide direct comfort to the seated occupant. An intermediate pad 182 may be provided beneath the trim cover 180 for an additional transition from contact to comfort, and support. The comfort layers 174 and 176 could be attached to the trim cover 180 by sewing, or the like. The trim cover 180 could be attached to the support layers 172, 176 by clips, hook and loop fasteners, rings, and the like.

FIG. 14 illustrates a seat assembly 210 according to another embodiment. The seat assembly 210 may employ any of the features set forth in the prior embodiments. The seat assembly 210 includes a seat bottom 212, and a seat back 214. The seat assembly 210 may be formed without foam to improve comfort, performance, compactness, and recycling, while reducing manufacturing tooling costs. For example, the seat assembly 210 includes a seat bottom support 216, which provides the seat bottom cushion for the seat bottom 212. The seat bottom support 216 is formed from a plurality of stacked layers of a non-foam material. The seat back 214 includes a seat back support 218 that is also formed of the non-foam stacked layers.

The seat bottom support 216 includes a seat bottom base layer 222 and a seat bottom comfort layer 224. The seat back support 218 also includes a seat back base layer 226 and a seat back comfort layer 228. The seat bottom base layer 222 and the seat back base layer 226 are formed from a knitted monofilament textile material. The base layers 222, 226 are knitted or woven to provide structure, while the material is also spaced out to provide porosity, ventilation, and compliancy. The base layers 222, 226 may each vary by firmness or thickness and may be contoured to form a shape of the seat bottom support 216 and the seat back support 218, respectively. The base layers 222, 226 may be formed from an extruded plastic mesh material.

The seat bottom comfort layer 224 and the seat back comfort layer 228 are also formed from a knitted monofilament textile material as disclosed in Duncan et al. U.S. Pat. No. 10,736,435 B2, which issued to Lear Corporation on Aug. 11, 2020, and is incorporated in its entirety by reference herein. The material is knitted or woven to provide structure, while also spaced out to provide porosity, ventilation, and compliancy. Alternatively, the layers 224, 228 may each have a uniform thickness, and may be formed from sheets, or rolled sheets of material. The layers 224, 228 may each vary by firmness or thickness.

FIGS. 15 and 16 illustrate a seat assembly 190 according to another embodiment. The seat assembly 190 may employ any of the features set forth in the prior embodiments. The seat assembly 190 is illustrated as a rear row vehicle bench seat 190, according to an embodiment. The seat assembly 190 is illustrated with a trim cover removed therefrom. The seat assembly 190 includes a seat bottom 192, and a seat back 194.

The seat assembly 190 is formed without foam to improve comfort, performance, compactness, and recycling, while reducing manufacturing tooling costs. For example, the seat assembly 190 includes a seat bottom support 196, which provides the seat bottom cushion for the seat bottom 192. The seat bottom support 196 is formed from a plurality of stacked layers of a non-foam material. The seat back 194 includes a seat back support 198 that is also formed of the non-foam stacked layers.

The seat bottom support 196 and the seat back support 198 are formed from a knitted monofilament textile material. The seat bottom support 196 and the seat back support 198 may be formed from a plurality of layers, each layer formed from a knitted monofilament textile material. The seat bottom support 196 and the seat back support 198 are knitted or woven to provide structure, while the material is also spaced out to provide porosity, ventilation, and compliancy. The seat bottom support 196 and the seat back support 198 may each vary by firmness or thickness and may be contoured to form a shape of the seat bottom support 196 and the seat back support 198, respectively. An example of the knitted non-foam material of the base layers is disclosed in Duncan et al. U.S. Pat. No. 10,736,435 B2, which issued to Lear Corporation on Aug. 11, 2020, and is incorporated in its entirety by reference herein.

The seat bottom support 196 and the seat back support 198 may be produced with resin materials, such as linear low-density polyethylene (LLDPE), thermoplastic elastomer (TPE), high-density polyethylene (HDPE), or the like. The seat bottom support 196 and the seat back support 198 may each be fabricated through a forming operation, such as knitting, weaving, printing, or the like. The seat bottom support 196 and the seat back support 198 may each be formed from extruding, cutting, or the like.

While various embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention. 

What is claimed is:
 1. A seat support comprising a plurality of layers of a non-foam material to mount to a seat frame and to support an occupant upon the seat frame, wherein the plurality of layers is stacked upon each other, and at least one of the plurality of stacked layers has a generally uniform thickness.
 2. The seat support of claim 1 wherein the plurality of layers further comprises: a base layer to mount to the seat frame; and a second layer mounted to the base layer, wherein the second layer has the generally uniform thickness.
 3. The seat support of claim 2 wherein the base layer has a first firmness; and wherein the second layer has a second firmness that is less firm than the first firmness.
 4. The seat support of claim 2 wherein the base layer has a first thickness; and wherein the second layer has a second thickness that is less than the first thickness.
 5. The seat support of claim 2 wherein the base layer is formed from a monofilament textile material.
 6. The seat support of claim 2 wherein the second layer is formed from a monofilament textile material.
 7. The seat support of claim 2 wherein the second layer is formed from polyester.
 8. The seat support of claim 2 wherein the second layer is welded, sewn, or adhered to the base layer.
 9. A seat assembly comprising: a substrate; and the seat support of claim 2 attached to the substrate.
 10. The seat assembly of claim 9 further comprising the seat frame, wherein the substrate is attached to the seat frame.
 11. A seat assembly comprising: the seat support of claim 2; and a trim cover sized to receive the seat support with the second layer oriented between the trim cover and the base layer.
 12. The seat support of claim 1 further comprising a plurality of zones, wherein at least two of the zones vary in thickness, or firmness.
 13. The seat support of claim 12 wherein the plurality of zones further comprises a nose, an insert, and a pair of bolsters on opposed lateral sides of the nose and the insert to support a seat bottom.
 14. The seat support of claim 12 wherein the plurality of zones further comprises an insert, a pair of bolsters on opposed lateral sides of the insert, and a pair of shoulders on opposed lateral sides of the insert to support a seat back.
 15. A method for manufacturing a seat assembly comprising: forming a base seat support portion; cutting a second seat support portion from a sheet of monofilament material; and installing the second seat support portion upon the base seat support portion.
 16. The method of claim 15 further comprising installing a trim cover over the base seat support portion and the second seat support portion so that the second seat support portion is oriented between the base seat support portion and the trim cover.
 17. The method of claim 15 further comprising fastening the second seat support portion to the base seat support portion.
 18. The method of claim 15 further comprising forming the base seat support portion from a non-foam material.
 19. A seat assembly manufactured according to the method of claim
 15. 20. A method for manufacturing a seat assembly comprising: forming a base seat support portion from a non-foam material; cutting a second seat support portion from a sheet of monofilament material; installing the second seat support portion upon the base seat support portion; fastening the second seat support portion to the base seat support portion; and installing a trim cover over the base seat support portion and the second seat support portion so that the second seat support portion is oriented between the base seat support portion and the trim cover. 